EP0916634A2 - Méthode pour la production de fibre mécanique du genre collant et pièces de moteurs fabriquées à partir de celles-ci - Google Patents

Méthode pour la production de fibre mécanique du genre collant et pièces de moteurs fabriquées à partir de celles-ci Download PDF

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Publication number
EP0916634A2
EP0916634A2 EP98118092A EP98118092A EP0916634A2 EP 0916634 A2 EP0916634 A2 EP 0916634A2 EP 98118092 A EP98118092 A EP 98118092A EP 98118092 A EP98118092 A EP 98118092A EP 0916634 A2 EP0916634 A2 EP 0916634A2
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European Patent Office
Prior art keywords
fibers
woven fabric
raw material
hot
fiber
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EP98118092A
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German (de)
English (en)
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EP0916634A3 (fr
Inventor
Shouju Masaki
Takemi Yamamura
Tetsurou Hirokawa
Takeshi Tanamura
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Shikibo Ltd
IHI Corp
Ube Corp
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Shikibo Ltd
IHI Corp
Ube Industries Ltd
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Publication of EP0916634A2 publication Critical patent/EP0916634A2/fr
Publication of EP0916634A3 publication Critical patent/EP0916634A3/fr
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/64—Burning or sintering processes
    • C04B35/645—Pressure sintering
    • C—CHEMISTRY; METALLURGY
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    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/14—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silica
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/46—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on titanium oxides or titanates
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/62227—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products obtaining fibres
    • C04B35/62272—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products obtaining fibres based on non-oxide ceramics
    • C04B35/62277—Fibres based on carbides
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/62227—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products obtaining fibres
    • C04B35/62272—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products obtaining fibres based on non-oxide ceramics
    • C04B35/62277—Fibres based on carbides
    • C04B35/62281—Fibres based on carbides based on silicon carbide
    • C—CHEMISTRY; METALLURGY
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/62605—Treating the starting powders individually or as mixtures
    • C04B35/62645—Thermal treatment of powders or mixtures thereof other than sintering
    • C04B35/6265—Thermal treatment of powders or mixtures thereof other than sintering involving reduction or oxidation
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/628—Coating the powders or the macroscopic reinforcing agents
    • C04B35/62844—Coating fibres
    • C04B35/62847—Coating fibres with oxide ceramics
    • C04B35/62849—Silica or silicates
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/628—Coating the powders or the macroscopic reinforcing agents
    • C04B35/62897—Coatings characterised by their thickness
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/632—Organic additives
    • C04B35/6325—Organic additives based on organo-metallic compounds
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/71—Ceramic products containing macroscopic reinforcing agents
    • C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
    • C04B35/80—Fibres, filaments, whiskers, platelets, or the like
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D25/00—Woven fabrics not otherwise provided for
    • D03D25/005—Three-dimensional woven fabrics
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/48—Organic compounds becoming part of a ceramic after heat treatment, e.g. carbonising phenol resins
    • C04B2235/483—Si-containing organic compounds, e.g. silicone resins, (poly)silanes, (poly)siloxanes or (poly)silazanes
    • C—CHEMISTRY; METALLURGY
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/5252—Fibers having a specific pre-form
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/95—Products characterised by their size, e.g. microceramics
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2101/00—Inorganic fibres
    • D10B2101/02—Inorganic fibres based on oxides or oxide ceramics, e.g. silicates
    • D10B2101/08—Ceramic

Definitions

  • This invention relates to a fiber bond type ceramic material and more particularly to a method for the production of a ceramic material of the type having fibers three dimensionally bonded thereto and engine parts formed of the material.
  • the Tyranno fibers are inorganic fibers of Si-M-C-O synthesized by melt spinning polymetalocarbosilane, then infusibilizing the produced threads, and firing the set threads.
  • the Tyrannohex (Si-M-C-O fiber-bond type ceramic) material is produced by heat-treating the Tyranno fibers in the air and obtaining oxidized Tyranno fibers having an oxide layer on the surface thereof, preparing unidirectional prepreg sheets from the fibers, superposing the sheets uniformly in alignment, and compressing the superposed sheets with a hot press machine at an elevated temperature.
  • the Tyrannohex material constructed as described above, a matrix layer has been formed by hot-pressing oxided fibers and the gaps intervening between the adjacent fibers are uniformly filled with the oxide formerly existent on the surface of the raw material fibers and consequently allowed to form a dense texture veritably destitute of pores. Further, sine the Tyranno fibers themselves possess high mechanical properties and excellent heat-resistance and oxidation-resistance, the Tyrannohex material likewise excels in mechanical strength and in heat-resistance and oxidation-resistance.
  • the Tyrranohex material however, has the problem of readily sustaining a tear when it is cut in fabricating a turbine part.
  • a unidirectional Tyrannohex material is clamped in a vice and a cut is inserted in the material in a direction perpendicular to the fibers therein, for example, the complex stress originating in the friction resistance generated by the rotation of a grindstone and the rotation moment generated during the course of cutting under the own weight of the grindstone possibly acts on the boundaries of fibers and causes separation of the fibers in the interfaces.
  • the Tyranno fibers are two-dimensionally woven and they are superposed to produce a Tyrannohex material for the purpose of overcoming the problem mentioned above, the Tyrannohex material has the problem of readily sustaining separation of superposed weaves in the interfaces when the material is subjected to a machining work.
  • an attempt to produce a Tyrannohex material by orthogonally weaving Tyranno fibers in such a construction as contains fibers parallelly to the direction of compression for the purpose of preduding this separation is at a disadvantage in suffering the raw material fibers, during the course of hot-press fabrication, to form kinks and incur a heavy loss of strength, produce voids readily therein, and prevent formation of a dense matrix layer, with the result that the produced Tyrannohex material will have an unduly low volumetric fiber content and will betray serious degradation of heat-resistant strength.
  • this invention has been created with a view to solving the problems mentioned above. Specifically, this invention has for an object thereof the provision of a method for the production of a fiber-bond type 3 dimensionally strengthened ceramic material which incurs no easy occurrence of a peel or crack in the boundary faces or superposed faces of fibers, suffers only sparingly the raw material fibers during the course of hot-press fabrication to sustain an injury or produce voids therein, consequently enables these raw material fibers to form a dense matrix layer, and allows the produced ceramic material to acquire a high fiber content and engine parts made of the ceramic material.
  • a method for the production of a fiber-bond type ceramic material characterized by using as raw material fibers inorganic fibers of Si-M-C-O synthesized by melt spinning polymetalocarbosilane, then infusibilizing the produced threads, and firing the set threads, forming from the raw material fibers a woven fabric having all the fibers thereof extended perpendicularly or obliquely relative to the direction of compression during the course of a hot-press fabrication, heat-treating the woven fabric in the air thereby preparing a woven fabric of oxidized fibers provided with an oxide layer on the surface thereof, and subjecting the woven fabric of oxidized fibers to a hot-press fabrication while compressing the fabric in the direction of compressing mentioned above thereby causing the oxide layers on the surface to adhere fast to each other and form a matrix.
  • the compressing force exerted during the course of the hot-press fabrication acts in the lateral direction on the fibers.
  • the fibers therefore, do not easily sustain a kink or a shear.
  • the compressing force acts in the direction of contracting the distances between the fibers, the fibers produce no void therein and allow formation of a dense matrix layer.
  • the fiber-bond type ceramic material to be produced therefore, has a high fiber volumetric content and high heat-resistant strength.
  • the ceramic material having the fibers three-dimensionally bonded thereto does not suffer ready occurrence of a peel or crack in the boundary faces or superposed faces of fibers because it acquires a dense texture containing very few pores between the fibers.
  • the engine parts which are produced by shaping the fiber-bond type ceramic material manufactured as described above do not allow easy occurrence of a peel or crack in the boundary faces or superposed faces of the fibers.
  • a biaxial three-dimensional woven fabric is formed by preparing wefts and warps both of the raw material fibers, laying the wefts in numerous layers, and causing the warps to intersect each other as laid between two or more layers of wefts.
  • a woven fabric by preparing biaxial two-dimensional planar woven fabrics using wefts and warps both of the raw material fibers, superposing the planar woven fabrics, and uniting the superposed woven fabrics with obliquely intersecting third threads.
  • the compressing force of the hot-press fabrication can be caused to act nearly perpendicularly on the wefts and warps and obliquely on the third threads and enabled to ensure production of a fiber-bond type ceramic material of dense texture.
  • a woven fabric by preparatorily interlacing raw material fibers with short fibers of identical substance thereby forming short fiber-bound fibers and superposing these fibers as aligned perpendicularly to the direction of compression.
  • the compressing force generated during the course of the hot-press fabrication can be caused to act perpendicularly on the fibers, preclude the occurrence of kinks in the fibers due to the contraction during the course of the hot-press fabrication, and minimize the possible formation of voids in the interfaces and consequently enabled to ensure relatively inexpensive production of a fiber-bond type ceramic material.
  • Fig.1 is a flow diagram illustrating the method of the present invention.
  • the method for the production of a fiber-bond type ceramic material according to this invention comprises a weaving step 12 for forming a woven fabric 2 from raw material fibers 1, an oxidizing step 14 for oxidizing the woven fabric, and a hot-press step 16 for subjecting an oxidized woven fabric 3 to a hot-press treatment.
  • the raw material fibers 1 are the Tyranno fibers mentioned above, namely inorganic fibers of Si-M-C-O synthesized by melt spinning polytitanocarbosilane, then infusibilizing the produced threads, and firing the set threads.
  • the oxidizing step 14 consists in heat-treating the woven fabric 2 in the air and consequently converting it into the oxidized fiber woven fabric 3 provided on the surface thereof with an oxide layer.
  • This step consists in performing the heat-treatment in the air kept in about 1150°C for 10 - 40 hours thereby forming on the surface of the raw material fibers the oxide layer having an average thickness in the approximate range of 250- 600nm.
  • the hot-press step 16 consists in subjecting the woven fabric 3 formed of oxidized fibers to a hot-pressing fabrication while compressing it in a direction nearly perpendicular to the component fibers thereof thereby causing the oxidized layers on the surface to adhere intimately mutually and form a matrix. This step is properly performed in a vacuum at an elevated temperature in about 1750°C under a pressure of about 50 MPa. This step completes a fiber-bond type ceramic material 4.
  • Fig. 2A is a model diagram illustrating the first method for the formation of the woven fabric 2
  • Fig.2 B is a model diagram illustrating the second method for the formation thereof.
  • the first method of Fig. 2 A forms a biaxial three-dimensional woven fabric by dividing the raw material fibers into wefts 1a and warps 1b, laying the wefts 1a extending in the direction of y (the direction perpendicular to the surface of this paper) in a multiplicity of layers, and causing the warps 1b extending in the direction of x while undulating vertically in the direction of z to intersect alternating groups each of not less than two layers of the wefts 1a.
  • the construction of Fig. 2A-a uses the wefts 1a as divided into bundles each of two wefts and that of Fig. 2A-b uses the wefts 1a as divided independently of each other.
  • the warps 1a and the wefts 1b are both extended nearly horizontally.
  • the compressing force produced during the course of the hot-press fabrication is caused to act in the vertical direction in the bearings of the diagram, the compressing force during the course of the hot-press fabrication acts nearly in the lateral direction on substantially all the fibers.
  • the fibers therefore, do not easily sustain a kink or a shear. Since the compressing force acts in the direction of contracting the distances between the adjacent fibers, the fibers are allowed to form a dense matrix layer without giving rise to voids. Consequently, a fiber-bond type ceramic material retaining a high fiber content and having high heat-resistant strength can be produced.
  • the three-dimensionally integrated fiber-bond type ceramic material acquires a dense texture embracing very few pores between the fibers and, therefore, does not easily induce a peel or a crack in the boundary faces or superposed faces of the fibers.
  • the second method of Fig. 2B forms a woven fabric by dividing the raw material fibers 1 into wefts 1a and warps 1b, forming biaxial two-dimensional planar woven fabrics with the wefts 1a and the warps 1b, superposing the planar woven fabrics thereby forming a superposed-layer woven fabric, and integrating this superposed-layer woven fabric with obliquely and alternately intersecting third threads c.
  • Table 1 shows the test results obtained of the fiber-bond type ceramic materials produced by the methods of this invention described above.
  • Lox M grade Tyranno fibers were used as the raw material fibers 1.
  • the ratio (X : Y : Z) means the fiber volume ratio of wefts, warps, and third threads and the Vf (fiber volume fraction) means the volumetric proportion of the part having the fibers retain their shape during the formation of a woven fabric.
  • the bending strength (X direction and Y direction) denotes the maximum breaking stress manifested when the bending moment is exerted severally on the wefts and the warps.
  • Fig. 3A is a model diagram illustrating the third method and Fig. 3B a model diagram illustrating the fourth method for forming a woven fabric.
  • the woven fabric 2 having all the raw material fibers extended perpendicularly or obliquely therein relative to the direction in which the compression was applied during the course of the hot-press fabrication can be formed.
  • the third method of Fig. 3A (hereinafter referred to as "net shape weave”) comprises superposing the raw material fibers (in plane fibers 1a and 1b) as evenly arranged perpendicularly to the direction of compression, causing third threads 1c to intersect the inplane fibers obliquely as illustrated in the diagram, and allowing the inplane fibers 1a and 1b to be bundled between the surface and fourth fibers 1d.
  • the oblique direction of the third fibers 1c maybe wholly identical or maybe alternately reversed as indicated by a broken line in the diagram. This method nullifies the occurrence of kinks due to the compression during the course of hot-press fabrication and minimizes the occurrence of voids liable to form in the fibers.
  • the fourth method of Fig. 3B forms a woven fabric-by preparing short fiber-bound fibers having raw material fibers 1 interlaced in advance with short fibers 5 of identical substance and superposing these fibers perpendicularly to the direction of compression as illustrated in Fig. 3B-a.
  • This method likewise enables the compressing force generated during the course of the hot-press fabrication to act perpendicularly on the raw material fibers and, at the same time, nullifies the occurrence of kinks due to the compression during the course of hot-press fabrication and minimizes the occurrence of voids liable to form in the fibers and, therefore, allows relatively inexpensive production of a fiber-bond type ceramic material.
  • This method permits use of fibers which possess fluffs in themselves as illustrated in Fig. 3B-c.
  • the method of this invention for the production of a fiber-bond type ceramic material and the engine parts made of this ceramic material can bring about prominent effects such as, for example, rendering difficult the occurrence of a peel or a crack in the boundary faces or superposed faces of fibers, allaying the injury inflicted on the raw material fibers by the impact of the hot-press fabrication, precluding easy formation of voids between the raw material fibers, and consequently allowing formation of a dense matrix layer and impartation of a high volumetric fiber content to the material as described above.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Textile Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Nanotechnology (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Woven Fabrics (AREA)
  • Laminated Bodies (AREA)
EP98118092A 1997-09-25 1998-09-24 Méthode pour la production de fibre mécanique du genre collant et pièces de moteurs fabriquées à partir de celles-ci Withdrawn EP0916634A3 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP9260347A JPH11100281A (ja) 1997-09-25 1997-09-25 繊維結合型立体セラミックスの製造方法とそのガスタービン部品
JP260347/97 1997-09-25
JP26034797 1997-09-25

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EP0916634A2 true EP0916634A2 (fr) 1999-05-19
EP0916634A3 EP0916634A3 (fr) 2000-09-13

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US (1) US6245283B1 (fr)
EP (1) EP0916634A3 (fr)
JP (1) JPH11100281A (fr)

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DE202006008868U1 (de) * 2006-06-06 2006-08-03 Sefar Ag Gewebe, insbesondere für textile Bauten und/oder Abdeckungen
JP4784533B2 (ja) * 2007-03-09 2011-10-05 宇部興産株式会社 ＳｉＣ繊維結合型セラミックスの製造方法
CN105808644A (zh) * 2016-02-25 2016-07-27 浪潮软件集团有限公司 一种确定正文节点的方法及装置

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